Repositionable Display Panel

ABSTRACT

A repositionable display panel includes a rigid image plate that includes a front surface configured to receive a colorant to form an image thereon and a back surface opposite to the first surface. The rigid image plate is defined by an image plate thickness and image plate widths. A spacer block is defined by a spacer block thickness and spacer block widths smaller than the image plate widths. A pressure-sensitive adhesive layer between the back surface of the rigid image plate and the spacer block bonds the rigid image plate and the spacer block together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 17/095,167, filed Nov. 11, 2020, which is a continuation-in-part ofU.S. application Ser. No. 29/746,210, filed Aug. 12, 2020, thedisclosures of which are hereby incorporated by reference in theirentireties.

BACKGROUND OF THE INVENTION

The present application relates generally to technologies for producingcustomized image product, and in particular, to a personalized displaypanel that can be flexibly attached to a surface without altering thesurface.

In recent years, the popularization of digital media and digitalprinting technologies has created great demands for consumer productsdecorated with customized images. An important category of such productsare photo decor products that are used for decorating homes, offices,and public surroundings. Recently, there has been a surge in the demandfor personalized photo decor products in response to temporary andshort-term housing as well as the increased interest in more frequentchanges in decorations at home.

A drawback for most conventional photo display products is that theyrequire nails and fasteners to secure them on wall surfaces. There is aneed for personalized photo display products that can be decorate a wallwithout damaging it. There is also a need for photo decor products thatare portable and easily placed on walls.

SUMMARY OF THE INVENTION

In a general aspect, the present invention relates to a repositionabledisplay panel that includes a rigid image plate having a front surfacethat can receive a colorant to form an image thereon; and a back surfaceopposite to the first surface, wherein the rigid image plate is definedby an image plate thickness and image plate widths; a spacer blockdefined by a spacer block thickness and spacer block widths; and apressure-sensitive adhesive layer between the back surface of the rigidimage plate and the spacer block, wherein the pressure sensitive layercan bond the rigid image plate and the spacer block, wherein the spacerblock widths are smaller than the image plate widths.

Implementations of the system may include one or more of the following.When bonded together, an edge of the rigid image plate to an edge ofspacer block can be in the range of 1.5 to 5 times a thickness of thespacer block. The rigid image plate can be made of a metal, wood,plastics, a composite material, a glass, or ceramics. The rigid imageplate can include a colorant absorption layer on the front surface,wherein the image is formed by a colorant in the colorant absorptionlayer. The spacer block can be made of a foam material. Thepressure-sensitive adhesive layer can include an acrylic material or arubber-based material. The repositionable display panel can furtherinclude a double-sided adhesive tape comprising a first surfaceconfigured to be attached to a surface of the spacer block on anopposite side to the rigid image plate, wherein the double-sidedadhesive tape includes a second surface configured to be attached to awall surface. The pressure-sensitive adhesive layer can have a strongerbonding power than the double-sided adhesive tape. The colorant can betransferred to the front surface of the rigid image plate using thermaldye transfer or thermal sublimation to form the image on the frontsurface of the rigid image plate.

In another general aspect, the present invention relates to a method ofmanufacturing a repositionable display panel that includes forming animage on a front surface of a rigid image plate; placing the rigid imageplate with a back surface upward in an alignment fixture; receiving aspacer block having a surface attached with a pressure-sensitiveadhesive layer; removing a release liner from the pressure-sensitiveadhesive layer attached to the spacer block; placing the spacer block inthe alignment fixture with the pressure-sensitive adhesive layer facingdown; attaching the pressure-sensitive adhesive layer on the spacerblock to the back surface of the rigid image plate in in the alignmentfixture; loading an assembly of the rigid image plate and the spacerblock into an arbor press; and applying pressure on the spacer blockagainst the rigid image plate to activate a pressure-sensitive adhesivein the pressure-sensitive adhesive layer to bond the spacer block to therigid image plate to form a repositionable display panel.

Implementations of the system may include one or more of the following.The method can further include printing one or more alignment markers onan alignment sheet associated with the rigid image plate printed withthe image; attaching the alignment sheet on the back surface of therigid image plate; and aligning the spacer block relative to the rigidimage plate in the alignment fixture using the one or more alignmentmarkers before step of attaching. The step of aligning the spacer blockrelative to the rigid image plate can include aligning of the spacerblock relative to the rigid image plate in the alignment fixture usingthe one or more alignment markers. The method can further includeprinting product tracking information on the alignment sheet. The methodcan further include attaching a double-sided adhesive tape on the spacerblock of the repositionable display panel, wherein the repositionabledisplay panel is attached to a wall surface by the double-sided adhesivetape. The pressure-sensitive adhesive layer has a stronger bonding powerthan the double-sided adhesive tape, wherein the method can furtherinclude removing the repositionable display panel from the wall surfaceby detaching the double-sided adhesive tape from the wall surfacewithout breaking the pressure-sensitive adhesive layer.

The disclosed system and method can include one or more of the followingadvantages. The disclosed photo display product and the associatedmanufacturing method can provide personalized wall decorations withoutdrilling nails and damaging wall surfaces. The disclosed photo displayproduct is portable and can be conveniently positioned on and removedoff walls, which make them convenient for temporary or short-termliving. The disclosed photo display product also allows more frequentchanges of display content on a wall and allows for differentcombination of personalized photos on a wall surface. The disclosedphoto display product also does not require inserting prints into aframe as in some conventional display products.

These and other aspects, their implementations and other features aredescribed in detail in the drawings, the description and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a repositionable display panel inaccordance with some embodiments of the present invention;

FIG. 2 is a front perspective view of the repositionable display panelspaced away from a surface;

FIG. 3 is a side view of the repositionable display panel spaced awayfrom a surface;

FIG. 4 is a rear perspective view of the repositionable display panel;

FIG. 5 is a side perspective view of the repositionable display panel;and

FIG. 6 illustrates a process for manufacturing the repositionabledisplay panel in accordance with some embodiments of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to specific embodiments orfeatures, examples of which are illustrated in the accompanyingdrawings. Generally, corresponding reference numbers will be usedthroughout the drawings to refer to the same or corresponding parts.Also, wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or the like parts.

Referring to FIG. 1, a repositionable display panel 100 includes a rigidimage plate 110 that includes a front surface 111 and a back surface 112opposite to the first surface 111. The rigid image plate 110 is definedby an image plate thickness and image plate widths. The front surface111 is adapted to receive a colorant to form an image thereon. The rigidimage plate 110 includes a colorant absorption layer on the frontsurface 111. The image is formed by a colorant such as a dye or an inkin the colorant absorption layer. In some embodiments, the image isformed on the rigid image plate 110 using thermal dye transfer orthermal dye sublimation. In some embodiments, a colorant can be directlyprinted onto the front surface 111 of the rigid image plate 110.

The rigid image plate 110 can be made of a metal, wood, plastics, acomposite material, a glass, or ceramics. The rigid image plate 110 canhave width dimensions of 5′×7′, 8′×8′, 8′×10′, 10′×14′, etc., and iskept thin such as in a range of 0.030″ to 0.045″ and light weight sothat it can be securely attached to a wall surface with a removeabledouble-sided adhesive tape.

The repositionable display panel 100 also includes a spacer block 120adjacent to the back surface 112. The spacer block 120 is defined by aspacer block thickness and spacer block widths. The repositionabledisplay panel 100 further includes a pressure-sensitive adhesive layer130 between the back surface 112 of the rigid image plate 110 and thespacer block 120. The pressure-sensitive adhesive layer 130 bonds therigid image plate 110 and the spacer block 120 together. The spacerblock 120 is made of light and solid material such as a foam material.The pressure-sensitive adhesive layer 130 can be formed by an acrylic ora rubber-based material. In some embodiments, the spacer block 120 canalso be glued to the rigid image plate 110.

When the repositionable display panel 100 is attached to a wall fordisplay and decoration, as shown in FIGS. 2-3, the spacer block 120 cangive the appealing visual effect of “lifting” the rigid image plate 110off from the surface of the wall. The spacer block widths of the spacerblock 120 are substantially smaller than the image plate widths suchthat the spacer block 120 is hidden behind the rigid image plate 110 inmost viewing angles to the repositionable display panel 100 attached toa wall 200. The overall product specification and performance can dependon the dimensions of the rigid image plate 110 and the spacer block 120.Specifically, the difference between the widths of the rigid image plate110 and the widths of the spacer block 120 relative to the thickness ofthe spacer block are configured to provide the visual lifting effect asdescribed above. The above dimensions are such that the edge of therigid image plate to edge of spacer block is within a range of 1.5 to 5times or 2 to 4 times of the thickness of the spacer block. For example,for a rigid image plate 110 of 8″×8″ in widths, the spacer block 120have widths of 5″×5″ and ½″ in thickness. The outer edge of the spacerblock is thus inset from the back edge of the rigid image panel (110)approximately 1½″, which provides a ‘hidden’ lift appearance of thespacer block when viewed from most angles.

The pressure sensitive adhesive must cover a specific surface area toprovide enough strength so that a double-side adhesive tape 140(described below) removes from the wall when the product isrepositioned, the spacer block 120 does not detach from the rigid imageplate 110. The spacer block size provides the rigid image plate supportand a mechanical interface for the proper amount of double-sided tapesurface area (proportional to the adhesive strength) relative to overallproduct weight, to properly adhere to a wall and provide long-lastingadhesion without falling off. The ratios of these components result inthe balance and functionality of the product performance.

The back side of the repositionable display panel 100 is shown in FIGS.4-5. Other details of the repositionable display panel are disclosed inthe commonly assigned pending U.S. patent application Ser. No.29/746,210, titled “Repositionable Display Panel”, filed on Aug. 12,2020, the disclosure of which is incorporated herein.

When a user receives the repositionable display panel 100, he or she canremove a release liner from one side of a double-sided adhesive tape 140to attach a first surface to the spacer block on an opposite side to therigid image plate, and then remove a release liner from an oppositesurface to attach the repositionable display panel 100 to a wallsurface. The pressure-sensitive adhesive layer has a stronger bondingpower than the double-sided adhesive tape 140 which allows therepositionable display panel 100 to be detached from the wall surface bydetaching the double-sided adhesive tape 140 from the wall surfacewithout breaking the pressure-sensitive adhesive layer. The double-sidedadhesive tape 140 can have exemplified dimensions of 1″×4″ and a peelstrength of approximately ½ lb. per square inch, which can hold anexemplified weight of 0.26 lb. for the repositionable display panel.

Referring to FIG. 6, a process of manufacturing a repositionable displaypanel is now described. An image is formed on a front surface of a rigidimage plate (step 602). The rigid image plate can include a colorantabsorption layer on the front surface. The image can be formed on therigid image plate using thermal dye transfer or thermal dye sublimation.The image can also be direct printed to the rigid image panel. The rigidimage plate is placed in an alignment fixture with a back surface upward(step 604). The printed image is facing downward. A spacer block havinga surface attached with a pressure-sensitive adhesive layer is received.A release liner is removed from the pressure-sensitive adhesive layerattached to the spacer block (step 606) to expose the pressure-sensitiveadhesive to the air. The spacer block is placed in the alignment fixturewith the pressure-sensitive adhesive layer facing down (step 608). Thepressure-sensitive adhesive layer on the spacer block is attached to theback surface of the rigid image plate in in the alignment fixture (step610). Next, the assembly of the rigid image plate and the spacer blockis loaded into an arbor press (step 612). Pressure is then applied onthe spacer block against the rigid image plate to activate apressure-sensitive adhesive in the pressure-sensitive adhesive layer,which bonds the spacer block to the rigid image plate to form arepositionable display panel (step 614).

In some embodiments, an interim alignment sheet can be attached to backsurface of the rigid image plate, and moved together with the rigidimage plate printed with the image. The alignment sheet is printed withproduct, which includes product tracking information for tracking therigid image plate, the intermediate product assemblies, repositionabledisplay panel and the repositionable display panel. The productinformation can include consolidation order, sub-batch ID, orientation,date, printer identification that printed or transferred the image, anda barcode or a 2D matrix code that embeds with such information. Thealignment sheet can also be printed one or more alignment markers foraligning the spacer block to the rigid image plate. In the alignmentfixture, before step of attaching, the spacer block is aligned relativeto the rigid image plate using the one or more alignment markers on theback surface of the rigid image plate. The one or more alignment markerscan also include orientation indicators for aligning of the spacer blockrelative to the rigid image plate in the alignment fixture.

In some embodiments, using the alignment markers to guide theorientation, an operator removes one release liner of a double-sidedadhesive tape 140 (FIG. 1) and applies it to the upper portion of thespacer block on the back of a repositionable display panel. After acustomer receives the repositionable display panel, the customer removesanother release liner of the double-sided adhesive tape 140 on the backof the repositionable display panel, and attach it on to a wall 200(FIGS. 2 and 3). The pressure-sensitive adhesive layer has a strongerbonding power than the double-sided adhesive tape 140, which allows therepositionable display panel to be removed from the wall surface bydetaching the double-sided adhesive tape 140 from the wall surfacewithout breaking the pressure-sensitive adhesive layer 140 between thespacer block and the rigid image plate.

1-19. (canceled)
 20. A repositionable display panel, comprising: a rigidimage plate comprising a surface configured to receive a colorant toform an image thereon; a spacer block; and a pressure-sensitive adhesivelayer positioned between the rigid image plate and the spacer block,wherein the pressure-sensitive adhesive layer is configured to bond therigid image plate and the spacer block, and wherein the spacer block issmaller than the rigid image plate.
 21. The repositionable display panelof claim 20, wherein when bonded together, an edge of the rigid imageplate to an edge of the spacer block is in the range of 1.5 to 5 times athickness of the spacer block.
 22. The repositionable display panel ofclaim 20, wherein the rigid image plate is made of a metal, wood,plastics, a composite material, a glass, or ceramics.
 23. Therepositionable display panel of claim 20, wherein the rigid image plateincludes a colorant absorption layer on the surface of the rigid imageplate configured to receive the colorant, wherein the image is formed bythe colorant in the colorant absorption layer.
 24. The repositionabledisplay panel of claim 20, wherein the colorant is directly printed ontothe surface of the rigid image plate configured to receive the colorant.25. The repositionable display panel of claim 20, wherein the colorantis transferred to the surface of the rigid image plate configured toreceive the colorant using thermal dye transfer or thermal sublimationto form the image.
 26. The repositionable display panel of claim 20,wherein the spacer block is made of a foam material.
 27. Therepositionable display panel of claim 20, wherein the pressure-sensitiveadhesive layer comprises an acrylic material or a rubber-based material.28. The repositionable display panel of claim 20, further comprising: adouble-sided adhesive tape comprising a first surface configured to beattached to a surface of the spacer block on an opposite side to therigid image plate, wherein the double-sided adhesive tape includes asecond surface configured to be attached to a wall surface.
 29. Therepositionable display panel of claim 28, wherein the pressure-sensitiveadhesive layer has a stronger bonding power than the double-sidedadhesive tape.
 30. The repositionable display panel of claim 28, whereina surface area of the double-sided adhesive tape is relative to a weightof the repositionable display panel, and a surface area of thepressure-sensitive adhesive layer is proportional to the surface area ofthe double-sided adhesive tape.
 31. The repositionable display panel ofclaim 20, wherein the pressure-sensitive adhesive layer is positionedbetween the rigid image plate and the spacer block such that the imageformed on the surface of the rigid image plate is not obscured when therigid image plate and the spacer block are bonded by thepressure-sensitive adhesive layer.
 32. The repositionable display panelof claim 20, wherein a width and a height of the spacer block aresmaller than a width and a height of the rigid image plate.
 33. Arepositionable display panel, comprising: a rigid image plate,comprising: a front surface configured to receive a colorant to form animage thereon; and a back surface opposite to the front surface; aspacer block; and a pressure-sensitive adhesive layer between the backsurface of the rigid image plate and the spacer block, wherein thepressure-sensitive adhesive layer is configured to bond the rigid imageplate and the spacer block, and wherein the spacer block is smaller thanthe rigid image plate.
 34. The repositionable display panel of claim 33,wherein when bonded together, an edge of the rigid image plate to anedge of the spacer block is in the range of 1.5 to 5 times a thicknessof the spacer block.
 35. The repositionable display panel of claim 33,further comprising: a double-sided adhesive tape comprising a firstsurface configured to be attached to a surface of the spacer block on anopposite side to the rigid image plate, wherein the double-sidedadhesive tape includes a second surface configured to be attached to awall surface.
 36. The repositionable display panel of claim 35, whereinthe pressure-sensitive adhesive layer has a stronger bonding power thanthe double-sided adhesive tape.
 37. The repositionable display panel ofclaim 35, wherein a surface area of the double-sided adhesive tape isrelative to a weight of the repositionable display panel, and a surfacearea of the pressure-sensitive adhesive layer is proportional to thesurface area of the double-sided adhesive tape.
 38. The repositionabledisplay panel of claim 33, wherein the rigid image plate is made of ametal, wood, plastics, a composite material, a glass, or ceramics. 39.The repositionable display panel of claim 33, wherein the spacer blockis made of a foam material.